Micromachined apparatus for improved reflection of light

ABSTRACT

A micromachined apparatus for reflecting light is described that is designed to reduce losses in quality or intensity of light. Mirrors are used having lengths that are longer than their widths to reduce clipping of light when a mirror is located at an angle with respect to light falling thereon. Relatively long mirror torsion components are used to reduce forces required to pivot the mirrors. Regardless of the dimensions of the mirrors and the use of long torsion components, the mirrors are still located relatively close to one another. The relatively close positioning of the mirrors is due to a combined use of notches formed in support frames to which the torsion components are secured, oval shapes of the mirrors which take up less space than rectangular shapes, matching oval openings in the support frames, and the arrangement of the support frames in a non-rectangular array wherein tips of the support frames are located between one another.

FIELD OF THE INVENTION

[0001] The invention relates to a micromachined apparatus for reflecting light.

BACKGROUND OF THE INVENTION

[0002] Optical fibers are commonly used in networks such as the Internet. Optical fibers are often bundled together in an array, each carrying different signals of light. In certain instances the signals of light carried by the different optical fibers have to be switched into a different arrangement. The optical fibers are provided as input fibers into an optical switch and further optical fibers are provided as output fibers from the optical switch. A micromachined apparatus for reflecting light from the input optical fibers is located in a path of light being emitted from the input optical fibers. The micromachined apparatus for reflecting light usually has an array of mirrors which are arranged in a manner similar to the input optical fibers. Each mirror reflects light from a respective input optical fiber to the output optical fibers. Each mirror can be pivoted so that the light reflected therefrom is directed to a selected one of the output optical fibers.

[0003] Losses in quality and intensity of the light used in such a switch may occur. Losses may be due to the mirrors being located too far apart or due to clipping of edges of bundles of light when the mirrors are located at an angle to the bundles of light. Locating the mirrors too close to one another may, however, require forces that are too high for purposes of pivoting the mirrors against torsion spring forces which tend to restore the mirrors.

SUMMARY OF THE INVENTION

[0004] A micromachined apparatus for reflecting light is provided comprising a support structure and a plurality of mirrors. Each mirror is pivotally secured to the support structure. A first to a third adjacent ones of the mirrors are located at corners of a first triangle. Each corner of the triangle is less than 90°.

[0005] Other features and advantages of the present invention will be apparent from the accompanying drawings and from the detailed description that follows below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:

[0007]FIG. 1 is a plan view of a micromachined apparatus for reflecting light according to an embodiment of the invention;

[0008]FIG. 2 is a cross-sectional side view on 2-2 in FIG. 1; and

[0009]FIG. 3 is a cross-sectional side view on 3-3 in FIG. 1.

DETAILED DESCRIPTION

[0010] A micromachined apparatus for reflecting light is described that is designed to reduce losses in quality or intensity of light. “Micromachined” refers to structures fabricated by selective etching or deposition. As described in more detail below mirrors are used having lengths that are longer than their widths to reduce dipping of light when a mirror is located at an angle with respect to light falling thereon. Relatively long mirror torsion components are used to reduce forces required to pivot the mirrors. Regardless of the dimensions of the mirrors and the use of long torsion components, the mirrors are still located relatively dose to one another. The relatively dose positioning of the mirrors is due to a combined use of notches formed in support frames to which the torsion components are secured, oval shapes of the mirrors which take up less space than rectangular shapes, matching oval openings in the support frames, and the arrangement of the support frames in a non-rectangular array wherein tips of the support frames are located between one another.

[0011]FIG. 1 to FIG. 3 of the accompanying drawings illustrate a micromachined apparatus 10 for reflecting light according to an embodiment of the invention. The apparatus 10 includes a substrate 12, a support structure 14, a plurality of support frames 16, and a plurality of mirrors 18 and may be manufactured utilizing photographic techniques, ion etching techniques or any other technique as will be evident to a person skilled in the art.

[0012] The support structure 14 is formed on the substrate 12 so as to be secured to the substrate 12. The support structure 14 is in the form of a honeycomb defining generally hexagonal openings. In one implementation, the substrate is fabricated from silicon, the support structure 14 is formed by a reactive ion etching of silicon, and the mirrors 18 are formed by etching silicon.

[0013] Each frame 16 is formed to define an oval opening 20. Deep notches 22A and 22B are formed in a surface of the oval opening 20. The notches 22A and 22B are formed at 0° and 180° about the oval opening 20, respectively. Notches 24A and 24B are also formed in an outer surface of the frame 16. The notches 24A and 24B are located at 90° and 270° on the outer surface of the support frame 16.

[0014] The oval shape 20 has a length L1 and a width W1. The length L1 extends between the notches 22A and 22B and the width W1 between the notches 24A and 24B. The length L1 is typically about 320 micron and the width W1 is about 270 micron. The oval shape 20 thus has a long axis between the notches 22A and 22B. Because of the oval shape 20 and its orientation, and to allow for the notches 22A and 22B to be formed, the frame 16 has a length L2 and a width W2wherein the length L2 is much larger that the width W2. The frame 16 thus takes up more space along its length L2 than along its width W2. The length L2 is typically about 520 micron and the width W2 about 340 micron.

[0015] Each frame 16 is located within a respective opening in the support structure 14 and is secured to the support structure 14 with two frame torsion components 26. Each frame torsion component 26 has a first end 28 and a second, opposing end 30. The first end 28 is non-rotationally secured to the support structure 14. The frame torsion component 26 extends from the first end 28 into a respective one of the notches 24A or 24B, and the second end 30 is non-rotationally secured to the frame 16. The frame 16 is thereby suspended above the substrate 12 by the frame torsion components 26. The frame 16 has a minimum spacing S as measured from directly next to the notch 24A to the support structure 14. The frame torsion component 26 has a torsion length from the end 26 to the end 30 which is more than the minimum spacing S.

[0016] The frame 16 can be pivoted about an axis through the frame torsion components 26. The entire length of each frame torsion component 26, i.e. from its end 28 to its end 30, winds up, or twists against a torsion spring force thereof, thus tending to return the frame 16 to its original position. It can thus be seen that, although the minimum spacing S can be kept relatively small, each spring torsion component 26 has a torsion length that is relatively long, in particular longer than the minimum spacing S. By keeping the torsion length relatively long, a torsion spring constant of each spring portion component can be increased with a corresponding decrease in torsion required to pivot the frame 16 by a predetermined degree. The relatively long torsion length is allowed for due to the extra space provided by the notch 24A or 24B. Another thinner frame having less material may also provide a similar amount of space but may include too little material for purposes of strength. The notches 24A or 24B thus provide additional space while maintaining strength in the frame 16.

[0017] The frames 16 are located in a nonrectangular array. The frames 16A, 16B, and 16C pivot about a common frame axis 30 and the frames 16D, 16E, and 16F pivot about a common frame axis 32 which is parallel to and spaced from the frame axis 30. A line can be constructed from a center point of an oval opening 20 of one frame (e.g. 16A) to an oval opening 20 of an adjacent frame (e.g. 16D). By constructing such lines between adjacent oval openings 20, it can be seen that center points of the oval openings 20 are located at corners of contiguous triangles. For example, the oval openings 20 of the frames 16A, 16B, and 16D are located respectively at comers 40, 42, and 44 of one triangle. Each comer, 40, 42, and 44 is less than 90°. The comers 40 and 42 are equal to one another. By so locating the frames 16, a zigzag pattern is created following center points of oval openings of the frames 16A, 16D, 16B, 16E, 16C, and 16F.

[0018] Each oval opening 20 has a center line 46 extending along its length L1. The center line 46 of the oval opening 16D is spaced and parallel to the center line 46 of the oval opening 20 of the frame 16A. Similarly, the center line 46 of the oval opening 20 of the frame 16B is spaced and parallel to the center line 46A of the oval opening 20 of the frame 16D, and so on. By so locating the frames 16, a tip 50 of the frame 16D near the notch 22B thereof can be located between tips 52 and 54 of the frames 16A and 16B, respectively.

[0019] By locating the tip 50 between the tips 52 and 54, the center points of the oval openings of the frames 16A, 16B, and 16D can be located closer to one another. This can be accomplished even though each frame 16 has a relatively long length L2. The frames 16 are then located over a smaller area than would for example be possible in a rectangular array.

[0020] Each mirror 18 has an approximate oval shape with a length L3 and a width W3. The length L3 is typically about 300 micron and the width W3 about 250 micron. Each mirror 18 is located within a respective oval opening 20 with its length L3 along the length L1 of the oval opening 20 and its width W3 along the width W1 of the oval opening 20. Each mirror 18 is secured to a respective frame 16 with two mirror torsion components 54. Each mirror torsion component 54 has first and second opposed ends 56 and 58 respectively. The first end 56 is non-rotationally secured to the mirror 18. The mirror torsion component 54 extends from the first end 56 into a respective one of the notches 22A or 22B. The second end 58 of the mirror torsion component 54 is non-rotationally secured to the frame 16 within the notch 22A or 22B. The mirror 18 is thereby suspended within the oval opening 20 of the frame 16. A center point of the mirror 18 coincides with a center point of the oval opening 20. There is a minimum spacing M as measured from a surface of the mirror 18 to a surface of the oval opening 20 directly next to the notch 22A. Although the minimum spacing M is relatively small, the mirror torsion component 54 is relatively long due to the depth of the notch 22A while still maintaining strength of the frame 16.

[0021] The mirror can pivot relative to the frame 16 about the center line 46, whereupon each mirror torsion component 54 winds up, or twists against a torsion spring force thereof. The entire length of the mirror torsion component from the first end 56 to the second end 58 winds up, or twists. The length of each mirror torsion component 54 allows it to have a higher torsion spring constant with a corresponding smaller force being applied to rotate the mirror 18 by a certain degree.

[0022] Electrostatic terminals 64 are formed on the substrate 12. The electrostatic terminals 64 are used to pivot the frame 16 or the mirror 18 by electrostatic attraction. The support structure 14 also serves as an electrostatic barrier between electrostatic terminals and adjacent mirrors 18. The apparatus 10 may be used in an optical switch wherein a respective circular bundle of light shines from a respective optical fiber onto a respective one of the mirrors 18. The light may shine in a direction 66 which is at an angle 68 of, for example, 45° with respect to a plane in which the substrate 12 extends. A usable portion of the bundle of light falls between the width W3 of the mirror 18. The bundle of light is usually circular in cross section so that it typically has a usable length which equals its usable width. Because of its length L3 of the mirror 18, the entire usable length of the bundle of light falls on the mirror 18. The oval shape of the mirror 18 thereby allows for the entire usable width and length of the bundle of light to be reflected therefrom, even though the light shines in the direction 66 and even when the frame 16 is pivoted as shown in FIG. 2 so that the mirror 18 is pivoted with respect to the frame 16. It should be noted that the oval shape of each mirror 18 also makes more efficient use of space than for example a rectangular mirror, thereby allowing for the mirrors 18 and frames 16 to be located over a smaller area.

[0023] Mirrors 18 are thus used which have lengths L3 which are longer than their widths W3. In addition, relatively long mirror torsion components 54 and frame torsion components 56 are used. Regardless of the dimensions of the mirrors 18 and the torsion components 54 and 26, the mirrors 18 are still located relatively dose to one another. The relatively close positioning of the mirrors 18 is due to a combined use of a honeycomb support structure 14 which also serves as an electrostatic barrier, the notches 22A, 22B, 24A, 24B, the oval shapes of the mirrors 18 together with closely matching shapes of the oval openings 20, and the arrangement of the frames 16 in a non-rectangular array wherein a tip 50 can be located between the tips 52 and 54. By locating the mirrors closer to one another a smaller array is formed. A smaller array results in a smaller optical switch and a reducing in path length that light has to travel before reaching and after being reflected by a mirror. A reducing in path length of the light reduces losses in quality and intensity of light.

[0024] In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather that a restrictive sense. 

1. A micromachined apparatus for reflecting light, comprising: a support structure; and a plurality of mirrors each being pivotally secured to the support structure, a first to a third adjacent ones of the mirrors being located at corners of a first triangle, each corner being less than 90°.
 2. An apparatus according to claim 1 wherein the mirrors are located at corners of a plurality of contiguous triangles, each triangle having three corners, each of which is less than 90°.
 3. An apparatus according to claim 1 further comprising a plurality of support frames, each support frame being pivotally secured to the support structure, the first, second and third mirrors being secured to a first, second, and third of the support frames, respectively.
 4. An apparatus according to claim 3 wherein the third support frame is partially located between the first and second support frames.
 5. An apparatus according to claim 4 wherein a respective mirror pivots relative to a respective support frame about a respective mirror pivot axis, the mirror pivot axis about which the third mirror pivots being located between the mirror pivot axes about which the first and second mirrors pivot.
 6. An apparatus according to claim 1 further comprising an electrostatic barrier structure located between the first and second, the first and third, and the second and third mirrors.
 7. A micromachined apparatus for reflecting light, comprising: a support structure; a plurality of support frames pivotally secured to the support structure and being located in first and second substantially parallel lines, the support frames in the first line pivoting about a first support frame axis and the support frames in the second line pivoting about a second support frame axis which is spaced and substantially parallel to the first support frame axis, a respective support frame in the second line being partially located between adjacent ones of the two of the support frames in the first line; and a plurality of mirrors, each being secured to a respective support frame so as to be pivotal about a respective mirror axis transverse to a respective support frame axis about which the support frame pivots.
 8. An apparatus according to claim 7 further comprising an electrostatic barrier structure located between the support frames and being formed so as to completely surround each support frame.
 9. A micromachined apparatus for reflecting light, comprising: a substrate; a support component secured to the substrate; a reflective component located next to the support component and having a predetermined minimum spacing from the support component; and a torsion connector having one end secured to the support component and a second opposing end secured to the support component, pivoting of the reflective component winding the torsion component against a torsion spring force thereof, a torsion length of the torsion spring component being more than the predetermined minimum spacing.
 10. An apparatus according to claim 9 wherein the support component is a support structure and the reflective component includes: a support frame, the torsion component being a frame torsion component securing the support fame to the support structure; and a mirror pivotally secured to the support frame.
 11. An apparatus according to claim 10 wherein the support frame has a surface from which the predetermined minimum spacing is measured to the support structure, and a notch formed in the surface, the torsion length of the frame torsion component extending into the notch.
 12. An apparatus-according to claim 9 further comprising: a support structure secured to the substrate, the support component being a support frame pivotally secured to the support structure, the reflective component being a mirror, and the torsion component being a mirror torsion component securing the mirror to the support frame.
 13. An apparatus according to claim 12 wherein the support frame has a surface from which the predetermined minimum spacing is measured to the mirror, and a notch being formed in the surface, the torsion length of the mirror torsion component extending into the notch.
 14. An apparatus according to claim 9 wherein a first to a third adjacent ones of the mirrors are located in a triangle having comers, each of which is less than 90°.
 15. An apparatus according to claim 14 wherein each mirror has a long axis and a short axis transverse to the long axis, the long axes of the first to the third mirror components being located parallel and spaced from one another.
 16. A micromachined apparatus for reflecting light, comprising: a support structure; and a plurality of mirrors secured to the support structure, each mirror having a substantially oval shape having a long axis and a short axis, the mirror being pivotal relative to the support structure about an axis transverse to the long axis thereof.
 17. An apparatus according to claim 16 further comprising a plurality of support frames, each being secured to the support structure, each mirror being secured to a respective support frame, each support frame being pivotal relative to the support structure so as to pivot the mirror about the axis transverse to the long axis thereof, and the mirror being pivotal relative to the support frame about an axis transverse to the short axis thereof.
 18. An apparatus according to claim 17 wherein the support frame defines an opening within which the mirror is located, the opening having a substantially oval shape.
 19. A micromachined apparatus for reflecting light, comprising: a support structure; a plurality of support frames each being pivotally secured to the support structure for pivotal movement about a respective support frame axis; and a plurality of mirrors each being pivotally secured to a respective support frame for pivotal movement about a respective mirror axis which is transverse to the respective support frame axis about which the respective support frame pivots, four adjacent ones of the mirrors being located in a zigzag arrangement with each subsequent mirror in the zigzag arrangement having its respective mirror axis spaced from the mirror axis of a previous mirror in the zigzag arrangement.
 20. An apparatus according to claim 19 wherein each support frame has a surface having a minimum predetermined spacing as measured to a respective mirror, a notch being formed in the surface, further comprising a plurality of mirror torsion components, each mirror torsion component having one end secured to a respective mirror, extending from the mirror into a respective notch and having a second, opposing end secured to a respective support frame, pivoting of the mirror winding the torsion component against a torsion spring force thereof.
 21. A micromachined apparatus for reflecting light, comprising: a support structure; a plurality of support frames each being pivotally secured to the support structure for pivotal movement about a respective support frame axis; and a plurality of mirrors each being pivotally secured to a respective support frame for pivotal movement about a respective mirror axis which is transverse to the respective support frame axis about which the respective support frame pivots, three adjacent ones of the mirrors being located in a non-rectangular array. 